Composite panels and methods for manufacture and installation thereof

Abstract

Panels usable for construction of a surface, to provide the surface with a desired appearance, durability, water, air, and fire resistance, dimensions, and weight include a layer of substrate material having first and second sides. Finish elements are positioned on the first side, while a backing material is positioned on the second side, such that the substrate bonds the finish elements to the backing material. Particulate material can also be included, such as within spaces between finish elements. Manufacture of such panels can include use of a vacuum system that acquires finish elements in a selected orientation, acquires particulate material into spaces unoccupied by finish elements, then deposits the arranged finish elements and particulate material into a mold for subsequent manufacturing steps. Use of lightweight, durable materials, such as magnesium oxide, can enable panels having a reduced thickness and weight to be manufactured, without sacrificing durability or longevity.

What is claimed is: 
     
       1. A method for manufacturing a panel, the method comprising the steps of:
 associating a vacuum device with a surface adapted to retain panel elements in association therewith in a selected orientation; 
 applying force from the vacuum device through the surface to associate a plurality of finish elements with a first zone of the surface, wherein said plurality of finish elements obstructs the first zone of the surface to define a second zone thereof between individual finish elements of the plurality of finish elements; 
 applying force from the vacuum device through the surface to associate particulate material with the second zone between the individual finish elements, thereby forming an assembly of panel components having the selected orientation; 
 transferring the plurality of finish elements and the particulate material to a mold device in the selected orientation; and providing an uncured substrate material and a sheathing material into the mold apparatus, applying at least one backing material to the plurality of finish elements and the particulate material, and permitting the uncured substrate material to cure, thereby binding the finish elements and the particulate material to the sheathing material to form the panel usable for construction of the surface. 
 
     
     
       2. The method of  claim 1 , wherein the step of associating the vacuum device with the surface comprises associating the vacuum device with a frame having the surface thereon, wherein the frame comprises a plurality of orifices for transmitting force from the vacuum therethrough. 
     
     
       3. The method of  claim 2 , wherein the step of associating the vacuum device with the surface further comprises providing at least one spacing member between the frame and the surface. 
     
     
       4. The method of  claim 1 , further comprising the step of providing a finish element storage receptacle into association with the surface, wherein the finish element storage receptacle comprises said plurality of finish elements therein, arranged in the selected orientation, and wherein the step of applying force from the vacuum device through the surface to associate the plurality of finish elements with the first zone comprises removing said plurality of finish elements from the finish element storage receptacle. 
     
     
       5. The method of  claim 1 , further comprising the step of applying force from the vacuum device through the surface to associate at least one barrier member with a portion of the second zone to define a third zone of the surface between individual finish elements of the plurality of finish elements and between the plurality of finish elements and said at least one barrier member. 
     
     
       6. The method of  claim 5 , wherein said at least one barrier member defines an external edge and prevents movement of the particulate material beyond the external edge. 
     
     
       7. The method of  claim 1 , wherein the step of applying the at least one backing material to the plurality of finish elements and the particulate material comprises providing an uncured substrate material and a sheathing material into the mold apparatus and permitting the uncured substrate material to cure, thereby binding the finish elements and the particulate material to the sheathing material to form the panel. 
     
     
       8. The method of  claim 7 , further comprising the step of providing a compression, a pressure, or combinations thereof to the mold apparatus, wherein the compression, the pressure, or combinations thereof causes the uncured substrate material to penetrate into interstices in the particulate material to form a matrix. 
     
     
       9. The method of  claim 8 , wherein the compression, the pressure, or combinations thereof further causes the uncured substrate material to penetrate into pores in the sheathing material. 
     
     
       10. The method of  claim 1 , wherein the step of applying said at least one backing material to the plurality of finish elements and the particulate material comprises applying an adhesive and a backing member to the plurality of finish elements and the particulate material. 
     
     
       11. The method of  claim 10 , wherein the backing member comprises magnesium oxide, and wherein the backing member is adapted to provide the panel with a reduced thickness, a reduced weight, or combinations thereof. 
     
     
       12. The method of  claim 1 , wherein the plurality of finish elements comprises magnesium oxide, and wherein the plurality of finish elements is adapted to provide the panel with a reduced thickness, a reduced weight, or combinations thereof. 
     
     
       13. The method of  claim 1 , further comprising the step of installing the panel within an exterior wall, an interior wall, a floor, a ceiling, a roof, a counter, a backsplash, a fence, or combinations thereof. 
     
     
       14. A method for manufacturing a panel, the method comprising the steps of:
 associating a vacuum device with a mold base comprising a surface, the surface being adapted to aid in retention of finish elements in association therewith in a selected orientation; 
 applying force from the vacuum device through the surface to retain a plurality of finish elements with a first zone of the surface, wherein said plurality of finish elements obstructs the first zone of the surface to define a second zone thereof between individual finish elements of the plurality of finish elements; 
 applying force from the vacuum device through the surface to retain particulate material with the second zone between the individual finish elements, thereby forming an assembly of panel components; 
 providing an uncured substrate material onto at least a portion of the plurality of finish elements and the particular material; 
 applying at least one backing panel to the plurality of finish elements, the particulate material, and the uncured substrate within the mold base; and 
 permitting the uncured substrate material to cure, thereby binding the finish elements and the particulate material to the backing panel to form the panel. 
 
     
     
       15. The method of  claim 14 , wherein the surface comprises a plurality of orifices for transmitting a suction force from the vacuum device therethrough. 
     
     
       16. The method of  claim 14 , further comprising the steps of:
 providing a panel element storage receptacle, wherein the panel element storage receptacle comprises said plurality of finish elements therein, arranged in the selected orientation; and 
 removing the plurality of finish elements from the panel element storage receptacle and positioning them onto the surface. 
 
     
     
       17. The method of  claim 14 , further comprising the step of:
 providing a compression, a pressure, or combinations thereof to the mold base, wherein the compression, the pressure, or combinations thereof causes the uncured substrate material to penetrate into interstices in the particulate material to form a matrix. 
 
     
     
       18. The method of  claim 14 , further comprising the step of installing the panel in connection with an exterior wall, an interior wall, a floor, a ceiling, a roof, a counter, a backsplash, a fence, or combinations thereof. 
     
     
       19. The method of  claim 14 , further comprising the step of installing the panel in connection with an exterior wall, an interior wall, a floor, a ceiling, a roof, a counter, a backsplash, a fence, or combinations thereof. 
     
     
       20. A method for manufacturing a panel, the method comprising the steps of:
 associating a vacuum device with a mold base comprising a surface, the surface being adapted to aid in retention of finish elements in association therewith in a selected orientation; 
 providing a panel element storage receptacle, wherein the panel element storage receptacle comprises a plurality of finish elements therein, arranged in a selected orientation; 
 removing the plurality of finish elements from the panel element storage receptacle and positioning them onto the surface 
 applying force from the vacuum device through the surface to retain the plurality of finish elements thereon with a first zone of the surface, wherein said plurality of finish elements obstructs the first zone of the surface to define a second zone thereof between individual finish elements of the plurality of finish elements; 
 applying force from the vacuum device through the surface to retain particulate material with the second zone between the individual finish elements, thereby forming an assembly of panel components; 
 providing an uncured substrate material onto at least a portion of the plurality of finish elements and the particular material; 
 applying at least one backing panel to the plurality of finish elements, the particulate material, and the uncured substrate within the mold base; and 
 providing a compression, a pressure, or combinations thereof to the mold base, wherein the compression, the pressure, or combinations thereof causes the uncured substrate material to penetrate into interstices in the particulate material to form a matrix, and thereby binding the finish elements and the particulate material to the backing panel to form the panel.